Rotatable spool distributor valve



June 13,

Filed April 8, 1960 1961 J. RUDELICK ROTATABLE SPOOL DISTRIBUTOR VALVE 2Sheets-Sheet 1 VI'IIIIIIIIIIIIIIIIIAI l {SM/@HW June 13, 1961 J.RUDELICK ROTATABLE SPOOL DISTRIBUTOR VALVE 2 Sheets-Sheet 2 Filed April8, 1960 United States Patent O ROTATABLE SPOOL` DISTRIBUTOR VALVE JohnRudelick, Milwaukee, Wis., assignor to Bruner Corporation, Milwaukee,Wis., a corporation of Wisconsin Filed Apr. 8, 1960, Ser. No. 20,930 12Claims. (Cl. 137-625.46)

This invention relates to valves, and has more particular reference toimprovements in distributor valves by which the operation of waterconditioning, treating, and/or softening systems is governed.

As is well known, water softening systems are provided with a control or`distributor valve, which normally functions to direct hard waterthrough the softener tank of the system and thus make softened wateravailable `for service. The same distributor valve, however, is alsooperable to govern regeneration of the ion exchange material containedin the water softener tank.

Most control or distributor valves heretofore incorporated in watersoftening systems were designed to effect service operation of theapparatus in one position of the valve, but such valves had to beactuated to several other positions in order to effect the various stepsof a complete regenerating cycle of the system. For example, it has beencustomary to begin regeneration with a backwashing operation, and tofollow successively thereafter with brining, and rinsing steps beforeagain restoring the system to service operation. Moreover, in some watersoftening systems it was customary to rinse brine from the ion exchangematerial in the softener tank in two stages, the first comprising a slowrinse operation and the other a fast rinse operation. The control ordistributor valve, of course, had to be actuated to effect each one ofthese operations or steps of the regenerating cycle, and to finallyreturn the system to its normal operating condition at the completion ofregeneration.

This invention concerns a distributor valve of the character describedwhich is constructed to effect normal service operation of a Watersoftening system in one position of the valve, and to effect completeregeneration of the system in only one other position of the valve.

Hence, it is an object of the invention to provide a control ordistributor valve which is especially suited for use with a Watersoftening system or the like, and which features a spool type valveelement that is rotatable between two angularly spaced positions toeffect service operation of the system in one position of rotation ofthe spool, and to effect regeneration of the system in the otherposition of rotation of the spool.

More specifically, it is an object of this invention to provide adistributor valve of the character described wherein a plurality oflands on the spool cooperate with a number of control ports in oneposition of rotation of the spool to effect normal service operation ofa water softening system having the valve incorporated therein, andwhich lands cooperate with the control ports in another position ofrotation of the spool to effect regeneration of the system during whichsuch steps as brining and rinsing may be successively and automaticallycarried out without disturbing the setting of the spool.

Water softening systems for which the distributor valve of thisinvention are ideally suited are disclosed in my' copending applicationsSerial No. 770,794 filed October 30, 1958, and Serial No. 859,871 filedDecember 16, 1959. These copending applications, though primarilyconcerned with water softening systems, more or less diagrammaticallydisclose the manner in which a distributor valve like that of thisinvention effects service and regenerating operation of the system inonly two positions of rotation of the valve spool.

In addition, this application is also related to my copendingapplication Serial No. 7,832 filed February l0, 1960, and entitledRotatable Spindle Valve. Application Serial No. 7,832, however, isparticularly directed to the construction of the valve of thisinvention, and to the method of making it.

In distinction, the invention herein presented is specilically directedto the porting of the valve, the manner in which the ports are arrangedwith respect to a plurality of lands on the rotatable valve spool, andthe manner in which the ports and lands cooperate to achieve normalservice operation of a water softening system in one position ofrotation of the spool and to successively achieve such regeneratingsteps as brining and rinsing in another position of rotation of thespool.

In a more specific sense, it is a purpose of this invention to provide adistributor valve of the character described featuring a rotatable spoolhaving a number of axially spaced circumferentially enlarged obliquelands thereon which completely encircle the spool and have theirperipheries in sealing engagement with the wall of the bore in which thespool is received, and wherein the ports, which are selectivelycommunicable with one another as a consequence of rotation of the valvespool between normal operating and regenerating positions, are arrangedin two groups, with those of one group opening radially through one sideof the valve body and those of the other group opening radially throughthe opposite side of the valve body.

With the above and other objects in view which will appear as thedescription proceeds, this invention resides in the novel construction,combination and arrangement of parts substantially as hereinafterdescribed and more particularly dened by the appended claims, it beingunderstood that such `changes in the precise embodiment of thehereindisclosed invention may be made as come within the scope of theclaims.

The accompanying drawings illustrate one complete example of thephysical embodiment of the invention constructed according to the bestmode so far devised for the practical application of the principlesthereof, and in which:

FIGURE l is a more or less diagrammatic view of a water softening systemgoverned by a distributor valve of this invention;

FIGURE 2 is an enlarged detail view of the distributor valve, showingthe control spool thereof in its normal operating position of rotation;and

FIGURE 3 is a view similar to FIGURE 2 but showing the control spool ofthe valve in its regenerating position of rotation.

For purposes of illustration, the distributor valve 5 of this inventionhas been shown incorporated in a Water softening system of the typeforming the subject of my copending application Serial No. 859,871 filedDecember 16, 1959. A complete disclosure of the system may be had byreference to said copending application, but for the purposes of thisinvention, it will suice to point out that the system comprises a watersoftening tank 6 containing granular ion exchange material, andregeneration apparatus including a brine making device 7, a brinestorage tank 8, and a brine valve 9.

The distributing valve 5 is identical to that which forms the subject ofmy copending application Serial No. 7,832 filed Feb. l0, 1960, to whichreference may be had for a more complete disclosure of the structurethereof. It comprises an elongated body 10` having a bore 11 extendinglengthwise between the front and rear ends of the body, and a spool 12rotatably received in the bore. The body is so connected by ducts withthe softening tank 6 and the regeneration apparatus that in one positionof rotation of its control spool 12, it directs fresh hard water intothe lower end of the softener tank and routes softened water issuingfrom the top of the tank to a service line.

In another position of rotation of the control spool 12, namely itsregenerating position, the distributor Valve of this inventiondisconnects the softener tank from the hard water source and the serviceline, directs brine into the top of the softener tank for regenerationof the ion exchange material therein, and routes the brine effluentissuing from the bottom of the tank to a drain line leading to a seweror the like.

When used with certain types of regeneration apparatus which is designedto dispense a predetermined quantity of brine for regeneration, thecontrol valve of this invention will also function to direct fresh rinsewater through the softener tank 6, following brining, while the controlspool 12 remains in its regenerating position.

As shown, the bore 11 may open to the rear of the valve body, but itterminates a short distance from the front of the body to open theretothrough a reduced bearing hole 14 coaxial with the bore. The controlspool 12 comprises an elongated spindle 15 of a diameter considerablyless than that of the bore 11, having its forward end journaled in andprojecting through the bearing hole 14 in the front of the body to theexterior thereof where it may have an actuating knob 16 aixed thereto.

The spindle 15 is constrained to rotate on the axis of the bore 11partly by reason of the reception of its front end in the bearing hole14 and partly because of the provision of front and rear seals 17 and18, respectively, on the spindle, which snugly but rotatably engage thewall of the bore. Each ofthe seals comprises a pair of axially spacedflanges 19 and 20 fixed on the spindle, and a resilient annular gasketor sealing ring 21 confined therebetween with its periphery in sealingengagement with the wall of the bore. The peripheries of the flanges 19and 2t), of course, need not have actual engagement with the wall of thebore.

The forward seal 17 may abut the rearwardly facing shoulder 22 formed atthe junction between the forward end of the bore 11 and the bearing hole14, so as to cooperate with a hub 23 on the rear of vthe actuating knobto preclude axial motion of the control spool relative to the valvebody.

To effect the control of a water softening system such as thatillustrated, the control spool is provided with three axially spacedcircumferentially enlarged lands 24, 25 and 26, each of which completelyencircles the spindle. The foremost land 24 is spaced a distancerearwardly from the yfront seal 17, and the rearmost land 26 may beclosely adjacent to the rear seal 18. The intermediate land 25 islocated substantially midway between the front and rear lands 24 and 26,respectively.

It is a feature of the distributor valve of this invention that thelands 24, 25 and 26 are formed at an oblique angle to the axis of thecontrol spool. The two rear lands 25 and 26 are disposed at the sameangle with respect to the spindle axis, but the foremost land 24 isdisposed at an angle opposite to that of the lands 25 and 26.

It is also a feature of the invention that each of the lands has agroove in its periphery in which an O-ring 28 is confined. These O-ringssnugly but rotatably engage the wall of the bore to have sealingrelationship therewith, Iwithout interfering with rotation of the spoolin the bore. Preferably the valve body is provided with a plastic liner80 for its bore, against the inner surface of which the O-rings 28 areengaged for smooth sliding as the Spood 12 is rotated. This liner andthe method of making the same are disclosed in my aforesaid copendingapplication Serial No. 7,832, to which reference may be made for furtherdetails.

In the normal operating position of the control spool 12, shown inFIGURES 1 and 2, the uppermost portion of the forward land 24 lies asubstantial distance ahead of the lowermost portion of the land, whilethe uppermost portion of each of the two rear lands 25 and 26 lies asubstantial distance rearwardly of the lowermost portion thereof.

An upper group of four ports open radially into the bore 11 at axiallyspaced locations. The foremost of the group of four comprises a 4firsttank port 30 which opens to the bore at a location just ahead of theforemost land 24, and connects with a passage 31 in the body that may becommunicated by a duct 32 with the top of the softener tank 6.

rfhe rearmost of the group of four comprises a second tank port 33 whichopens radially into the bore just behind the intermediate land 25 andconnects with the inner end of a passage 34 in the body that may becommunicated by a duct 35 with the lower end of the softener tank 6.

The two intermediate ports 36 and 37 of the group of four constitutebrine inlet and regenerating ports, respectively, which open to the bore11 at locations intermediate the two foremost lands 24 and 25 when thespool is in its normal position seen in FIGURES` l and 2. The brineinlet port 36 is adjacent to the rst tank port 30 and it opens to thebore 11 at a zone intermediate the front and rear portions of theforemost land 2,4. The port 36 also connects with a passage 38 in thevalve body which may be communicated by a duct 39 with a source ofbrine, namely the brine tank 8.

The regenerating port 37 is adjacent to the second tank port 33` andopens to the bore 11 at a zone which may be said to be bounded by theclosest portions of the two foremost lands 2-4 and 25. The regeneratingport 37 connects with a passage 40 in the valve body that may becommunicated by a duct 41 with the bottom of the brine valve 9.

A group of three axially spaced ports 44, `45 and 46, each openingradially into the bore 11 at the underside of the valve body,respectively provide service, inlet, and drain ports. The service port44 is foremost and opens into the bore at a zone intermediate the `frontand rear portions of the foremost land 24. Also, the port S4 connectswith a passage =47 in the valve body that may be communicated by a duct48 ywith the service lines to be supplied with soft water.

The intermediate or hard water inlet port 45 of the group of three opensinto the bore 11 at a zone intermediate the front and rear portions ofthe center land 25 of the control spool. The inlet port 45 connects witha passage 50 in the valve body which may be communicated by a duct 51with a source of fresh hard water under pressure.

The rearmost port y46 of the group of three constitutes a drain portwhich opens into the rear of the bore 11 at a location intermediate thefront and rear portions of the rearmost land 26. As shown, this port maybe restricted, and it connects with a larger passage 52 in the bodywhich may be communicated by a duct 53 with a suitable drain.

The regeneration apparatus 7-8-9 forms no part of the present invention,and for a complete disclosure thereof reference may be had to mycopending applications Serial Nos. 770,794 and 859,871, the latter ofwhich discloses brine making and dispensing apparatus which is identicalto that shown diagrammatically in FIGURE l.

It will here suffice to note that concentrated brine is formed in thebrine making unit 7 and is transferred to and stored in the tank `8 tolbe dispensed for regeneration of the ion exchange material in the watersoftener tank 6 under the control of the distributor valve 5 of thisinvention. Ihe brine making unit 7 includes a reservoir 55 having a port56 communicating its interior with that of the brine valve 9. The brinevalve houses an axially movable fluid pressure responsive piston 57which is biased downwardly toward a normal position in the bottomportion of the valve. The piston 57 serves as a valve element toselectively communicate a side valve port 58 with either the reservoirport 56 or a bottom valve port 60 with which the duct 41 connects. Theport 60 is thus communicated with the regenerating port 37 of thedistributor valve.

In the lower or normal position of the piston seen in FIGURE l, the port56 in the brine reservoir is communicated by the brine valve with thebrine storage tank 8, through a duct 61 leading from the side port 58into the top of the brine storage tank. Brine formed in the brine makingunit 7 thus may gravitate from the reservoir 55 down into the brinestorage tank 8, to displace water upwardly from the tank and into thereservoir 55, where it may combine with `salt in the brine making unitto generate more brine.

In the normal or soft water position of rotation of the control spool 12(FIGURES 1 and 2), the two rear lands 25 and 26 on the spool cooperateto establish mutually exclusive communication between the source waterinlet port `45 and the second tank port 33. Consequently hard water tobe softened may flow from the source thereof into and upwardly throughthe softener tank. The rearmost land 26 also precludes directcommunication between the drain port 46 and the remaining ports of thevalve. The foremost land 24 of the distributor valve establishesmutually exclusive communication between the service port 44 and thefirst tank port 30, to enable soft water issuing from the top of thesoftener tank to ow through the valve to the service lines.

Also in the normal position of rotation of the control spool shown inFIGURES l and 2, the brine inlet and regenerating ports 36 and 37,respectively, have direct communication with the space in the bore 11between the two foremost lands 24 and 25 on the spool. Hence, the ports36 and 37 may be said to communicate with one another at this time. Inthe water softening system illustrated, however, it is important to ventthe space beneath the piston 57 of the brine valve 9 to allow the pistonto descend whenever regeneration is terminated by rotation of thecontrol spool to its normal position seen in FIGURES l and 2.

Such venting of the space beneath the piston of the brine valve isyaccomplished by means of an axial passage 62 in the rear portion of thespool spindle. A reduced forward portion 63 of the venting passage opensradially, as at 64, into the space in the bore 11 between the twoforemost lands 24 `and 25 on the spool, and thus communicates with theregenerating port 37 in the valve body. The larger diameter rear portion65 of the Venting passage opens radially, as at 66, into the space inthe bore 11 rearwardly of the rearmost land 26 on the spool.

Hence, in the normal position of rotation of the control spool, the rearend of the venting passage 62 of the spool is in communication with thedrain port 46, while the forward end of the venting passage is incommunication with the regenerating port 37 to vent the space in thebottom of the brine valve 9 to the drain line.

Communication between the regenerating port 37 and the drain port 46,however, is controlled by a ball check valve 68 which normally engages arearwardly facing seat 69 at the junction between the small and largediameter portions of the venting passage. A light spring 70, confinedbetween the ball check Valve 68 and a plug 71 closing the rear portionof the venting passage, yieldingly maintains the check valve seated.

The check valve 68 is adapted to move olf of its seat 69 whenever thepiston 57 of the brine valve 9 descends in the body of the brine valveand forces liquid through the duct 41 back into the distributor valve,so that the liquid thus expelled from the bottom of the brine valve mayflow to drain through the venting passage 62. soon as the piston 57reaches its lowermost position in the body of the brine Valve, thespring 7i) recloses the ball check 68.

Rotation of the control spool 12 one-half a revolution to itsregenerating position seen in Figure 3 initiates regenerating cycle ofthe water softening system, during which concentrated brine and thenfresh rinse water is caused to ilow through the bed of ion exchangematerial in the softener tank. In the regenerating position of thecontrol spool, the foremost land 24 on the spool provides mutuallyexclusive communication between the first tank port 30 and the brineinlet port 36. Also, the two foremost lands 24 and 25 on the spoolcooperate to communicate the hard water inlet port 45 with both theregenerating port 37 and the service port 44, so that fresh hard wateris available to the service lines throughout the entire regeneratingcycle. The two rear lands 25 and 26 now cooperate to provide mutuallyexclusive communication between the second tank port 33 and the drainport 46. The rear land 26, however, blocks off communication between therear of the venting passage 62 and the drain port 46, so that theventing passage is now ineective.

Hard water entering the valve thus issues from the regenerating port 37and is led through the `duct 41 into the bottom of the brine valve 9, toforce the piston 57 thereof upwardly to a position blocking thereservoir port 56 and connecting the side port 58 of the brine valvewith the duct 41. Hence, fresh hard water is directed into the top ofthe brine storage tank t5 to expel concentrated brine therefrom throughits outlet 39.

The brine thus expelled from the storage tank flows through the duct 39back to the control valve, entering the same through the brine inletport 36 which is now in communication with the rst tank port 30. Brineis thus directed out of the first tank port and into the top of thesoftener tank, through the duct 32,. for downward flow through the bedof ion exchange material in the softener. The brine effluent whichissues from the lower end of the tank returns to the distributor valvethrough the duct 35 and the second tank port 33, for iiow to drain byreason of the communication between ports 33 and 46 in the regeneratingposition of the control spool.

It is important to note that both the brining and rinsing steps of theregenerating cycle are effected by the distributor valve as aconsequence of the flow of fresh water from the inlet 45 of the valve,out through its regenerating port 37. Because of this characteristic,the distributor valve of this invention may be used equally well withwater softening systems wherein a predetermined quantity of brine iseducted from a conventional brine tank as a consequence of the fiow offresh water through an injector, and fresh water continues to flow tothe softener tank after eduction of the entire predetermined charge ofbrine, to eifect rinsing of the softener tank. In that type of system,the regenerating port 37 would, of course, be connected with the inletof the injector, and the venting passage 62 in the spool could beeliminated.

The brining step of the regenerating cycle continues until the level ofconcentrated brine in the storage tank 8 drops to the level of the mouthof the brine outlet 39. When that occurs, only fresh water dischargesfrom the brine storage tank to automatically begin the rinsing step inthe regenerating cycle, without disturbing the position of the `controlspool 12. During the rinsing step, the fresh hard water ilowingdownwardly through the water softener tank 6 discharges from the bottomof the softener tank and is fed back through the distributor valve intothe drain duct 53.

After all of the brine has been rinsed from the softener tank, thecontrol spool of the distributor valve may be rotated in eitherdirection back to its normal position seen in FIGURES l and 2, to againplace the water softening apparatus in service condition.

While the distributor valve of this invention has been shown providedwith a control spool which is rotated manually between normal operatingand regenerating positions by means of the actuator knob 16, electricalspindle drive instrumentalities may be provided to automatically effectregeneration of the ion exchange material of the softener tank atperiodic intervals. Such instrumentalities, however, are disclosed inand form part part of my aforesaid copending application Serial No.859,871.

After the control spool has been rotated Iback to its normal operatingposition seen in FIGURES 1 and 2, the bottom of the brine valve 9 isvented to drain through the venting passage 62 in the spool. In theregenerating position of the spool, however, the rearmost land 26 of thespool closes off communication between the radial outlet 66 for the rearof the venting passage and the drain port 416, to prevent hard waterentering the inlet port 45 from being bypassed to the drain.

From the foregoing description taken ltogether with the accompanyingdrawings it will be readily apparent to those skilled in the art thatthis invention provides an improved distributor valve which isespecially suited for use' with water softening systems and the like,and which features such an arrangement of ports in the valve body andlands on a rotatable control spool in the body that normal operation ofa water softening system as well as complete regeneration of the systemare achieved by the valve as a consequence of actuation of the controlspool between only two positions of rotation.

What is claimed as my invention is:

1. In a distributor valve for water softeners and the like: an elongatedbody having a bore therein extending lengthwise between the front andrear ends of the body, and a number of ports opening into the bore, andeach leading to a passage in the body, a group of three of said portsbeing located at one side of the body and spaced different distancesfrom the front end thereof, and a group of four ports being located atanother side of the body and also spaced different distances from thefront end of the body; the front and rear ports of said group of fourrespectively providing first and second tank ports, and the twointermediate ports of said group of four comprising a brine inlet portadjacent to said first tank port and a regenerating port adjacent tosaid second tank port; the front and rear ports of said group of threerespectively providing service and drain outlet ports and theintermediate port of said group of three constituting an inlet port; aspool received in said bore for rotation between a normal operatingposition and a regenerating position, and having three axially spacedlands thereon encircling the spool and sealingly engaging the wall ofthe bore, said lands and the ports being so related to one another thatin the normal operating position thereof, the spool communicates theinlet port with the second tank port and communicates the rst tank portwith the service por-t, while in said regenerating position thereof, thespool communicates the inlet port with the regenerating port,communicates the iirst tank port with the brine inlet port, andcommunicates the second tank port with the drain port.

Z. The distributor valve of claim l, wherein the lands and ports are soarranged that the spool also provides communication between the inletand service ports in the regenerating position of the spool.

3. The distributor valve of claim 1, wherein the spool is formed tocommunicate the regenerating port with the drain port in the normaloperating position of the spool.

4. The distributor valve of claim 1, wherein the spool has an axialpassage therein the ends of which open into the bore at axially spacedlocations so related to the lands and to the ports as to communicate theregenerating port with the drain port in the normal operating positionof the spool.

5. The distributor valve of claim 4, further characterized yby theprovision of a normally closed check valve in said spool passagearranged to open rearwardly in consequence of the flow of fluid into thebore from said regenerating port in the normal operating position of thespool.

6. The distributor valve of claim 1, wherein the spool is provided withthree axially spaced oblique lands to control communication between theports, each of said lands completely encircling the spool and the tworearmost lands being at the same angle with respect to the spool axiswhile the foremost land is at an angle opposite to that of said rearmostlands.

7. The distributor valve of claim 6, wherein the foremost land providesfor selectively communicating the first tank port with either theservice outlet or brine inlet ports, and the two rearmost landscooperate to provide for selectively communicating the second tank portwith either the inlet or drain ports.

8. The distributor valve of claim 7, further characterized by the factthat the two foremost lands cooperate to close olf the brine inlet andregenerating ports from both the inlet port and the service outlet portin the normal operating position of the spool, and provide communicationbetween the inlet port and both the service outlet: and regeneratingports in the regenerating position of the spool.

9. The distributor valve of claim 8, wherein the spool has an axialpassage Itherein opening at its front to the space in the bore betweenthe two foremost lands and opening at its rear to the space in the borebehind the rearmost land, and wherein said passage cooperates with therearmost land to afford communication between the regenerating and drainports in only the normal operating position of the spool.

10. A distributor valve for water softeners and the like, of the typehaving an elongated body with a bore therein extending lengthwisebetween the front and rear ends of the body, and a spool rotatablyreceived in said bore for rotary movement between normal operating andregenerating positions, said valve being characterized by: sealing meansproviding uid tight seals between the spool and opposite end portions ofthe bore; the provision of three axially spaced circumferentiallyenlarged oblique lands encircling the spool intermediate said sealingmeans, the two rearmost lands being at the same angle with respect tothe spool axis and the foremost land being disposed at an angle oppositeto that of said rearmost lands, and the peripheries of all of said landshaving sealing engagement with the wall of the bore; the provision ofseven passages in the body each leading to a port that opens radiallyinto the bore, a group of three of said ports being located at one sideof the body and in axially spaced relation t0 one another, and a groupof four of said ports being located at the opposite side of the body andin axially spaced relation to one another; said ports and lands being soarranged with respect to one another that in the normal operatingposition of rotation of the spool, the space in the bore between the twoforemost lands is in direct communication with only the two intermediateones of said group of four ports, the space in the bore between the tworearmost lands is in direct communication with only the rearmost one ofsaid group of four ports and the intermediate one of said group of threeports, the space in the bore ahead of the foremost land is in directcommunication with only the foremost one of each group of ports, and thespace in the bore rearwardly of the rearmost land is in directcommunication with only the rearmost one of said group of three ports;while in the regenerating position of rotation of the spool, the spacein the bore ahead of the foremost land is in direct communication withonly the two foremost ones of the group of four ports, the space in thebore between the two foremost lands is in direct communication with onlythe rear one of said two intermediate ports and with the two foremostports of said group of three, and the space in the bore between the tworearmost lands is in direct communication with only the rearmost port ofeach group of ports.

11. The distributor valve of claim 10, further charac- 9 10 terized bythe provision of a passage in the spool affording References Cited inthe le of this patent bypass communication between the space in the boreI ED T T E behind the rearmost land and the space in the bore UN T S AES PAT NTS between the two foremost lands. Kronhelm --v- Nov- 231 12.The distributor valve of claim 11, further charac- 5 2908'898 MuellerOct' 13 1959 terized by the provision of a normally closed check valvein said spool passage, arranged to open in the rearward FOREIGN PATENTSdirection. 1,109,656 France Sept. 28, 1955

